Complete service repair manual Hyster H40-50J, H60JS (F003) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H40J, H50J, H60JS (F003) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 1,254 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Section
Part No.
SRM Number Rev Date
FRAME
910258
0100 SRM 0179
08/81
GM ENGINE
899766
0600 SRM 0003
08/03
PERKINS ENGINES 4.2032
910007
0600 SRM 0169
01/85
COOLING SYSTEM
897934
0700 SRM 0626
11/01
ROCHESTER CARBURETOR
910057
0900 SRM 0011
02/97
LPG FUEL SYSTEM
899772
0900 SRM 0015
09/93
OIL CLUTCH
910061
1200 SRM 0018
02/97
SINGLE-SPEED PS TRANSMISSION-REPAIR
910067
1300 SRM 0043
10/82
OIL CLUTCH TRANSMISSION
910069
1300 SRM 0059
03/97
DRIVE AXLE
910073
1400 SRM 0049
09/03
STEERING AXLE
899775
1600 SRM 0010
01/96
STEERING CONTROL UNIT
910076
1600 SRM 0054
10/03
MASTER CYLINDER
910082
1800 SRM 0013
02/97
BRAKE SYSTEM
910083
1800 SRM 0080
06/97
HYDRAULIC PUMP DRIVE ASSEMBLY
899779
1900 SRM 0064
07/97
HYDRAULIC GEAR PUMPS
910091
1900 SRM 0097
10/03
HYDRAULIC SYSTEM
910097
2000 SRM 0065
03/85
TILT CYLINDERS
910102
2100 SRM 0103
10/03
ALTERNATOR
899784
2200 SRM 0002
10/03
STARTER
910107
2200 SRM 0106
02/01
HIGH ENERGY IGNITION SYSTEM
899788
2200 SRM 0107
03/02
INSTRUMENT PANEL INDICATORS and SENDERS
910110
2200 SRM 0143
12/03
ELECTRICAL WARNING DEVICES
910111
2200 SRM 0144
05/97
ELECTRICAL SYSTEM TROUBLESHOOTING
899793
2200 SRM 0153
07/97
UPRIGHTS-REPAIR
910116
4000 SRM 0115
07/97
LIFT CYLINDERS
910119
4000 SRM 0135
10/03
UPRIGHTS-DESCRIPTION
899796
4000 SRM 0167
07/97
VISTA UPRIGHTS-DESCR /OPER
899797
4000 SRM 0197
01/97
VISTA UPRIGHTS-REPAIR
899798
4000 SRM 0198
05/97
PERIODIC MAINTENANCE
599903
8000 SRM 0180
05/85
CAPACITIES and SPECIFICATIONS
910246
8000 SRM 0181
06/83
DIAGRAMS
910247
8000 SRM 0182
08/81
INCH (SAE) and METRIC FASTENERS
910442
8000 SRM 0231
03/03
PART NO. 599895
Cooling System…..543
Safety Precautions Maintenance and Repair…..544
General…..547
Description…..548
Radiator…..548
Radiator Cap…..548
Thermostat…..548
Water Pump…..549
Fan and Fan Shroud…..549
Cooling System Checks…..549
Radiator…..549
Thermostat…..549
Water Pump…..550
Exhaust Leaks…..550
Fan and Fan Shroud…..550
Radiator Cleaning…..550
Drain…..550
Clean…..550
Fill…..551
Troubleshooting…..552
hyster-899766-08-03-srm0003…..555
toc…..555
GM Engines…..555
Safety Precautions Maintenance and Repair…..556
General…..559
Description…..559
Engine Removal and Installation…..561
Cylinder Head and Valve Mechanism Repair…..561
Cylinder Head, Remove…..561
Cylinder Head, Disassemble…..561
Clean and Inspect…..561
Valves and Valve Seats…..564
Studs for Rocker Arms…..564
Hydraulic Valve Lifters, Replace…..565
Hydraulic Valve Lifters, Clean and Inspect…..565
Cylinder Head, Assemble…..565
Cylinder Head, Install…..565
Valve Clearance, Adjust…..566
Rocker Arm Cover, Install…..567
Timing Gear Cover Repair…..567
Remove…..567
Install…..568
Camshaft Repair…..569
Remove…..569
Inspect…..569
Camshaft Bearing…..570
Remove…..570
Install…..570
Distributor Repair…..571
Remove…..571
Install…..571
Lubrication System Repair…..572
Oil Sump…..572
Remove…..572
Install…..572
Oil Pump…..572
Remove…..572
Disassemble and Repair…..572
Assemble…..573
Install…..573
Piston and Connecting Rod Assemblies Repair…..573
Connecting Rod Bearings, Replace…..573
Piston and Connecting Rod Assemblies, Remove…..574
Piston and Connecting Rod Assemblies, Disassemble…..575
Piston, Clean and Inspect…..575
Cylinder Bores, Inspect and Repair…..575
Piston Rings, Inspect…..576
Piston and Connecting Rod Assemblies, Assemble…..576
Piston and Connecting Rod Assemblies, Install…..578
Crankshaft Repair…..578
Main Bearings, Replace…..578
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)…..579
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P…..579
Remove…..581
Inspect and Repair…..581
Main Bearing and Journal Clearance, Check…..582
Install…..582
Flywheel and Flywheel Housing Repair…..583
Remove…..584
Ring Gear, Replace…..585
Install…..585
Cooling System Repair…..585
Coolant Pump…..585
Fan Drive…..585
Viscous Fan Drive…..585
Engine Specifications…..587
Engine Data…..587
Cylinder Head…..588
Hydraulic Valve Lifter…..588
Camshaft…..589
Pistons…..590
Cylinder Bore…..590
Crankshaft…..591
Connecting Rods…..591
Cooling System…..592
Lubrication System…..592
Torque Specifications…..592
Troubleshooting…..593
Alternator with Regulator…..655
Safety Precautions Maintenance and Repair…..656
General…..659
Description…..659
Alternator Repair…..661
Alternator Type A…..661
Remove and Disassemble…..661
Clean…..662
Assemble…..663
Install…..663
Alternator Type B…..666
Remove and Disassemble…..666
Clean…..666
Assemble…..667
Install…..668
General Check and Adjustment…..669
Low Output Check (Type A or Type B)…..669
High Output Check (Type A or Type B)…..671
Brushes Circuit Check…..672
Delco Alternators…..672
Motorola Alternators…..673
Diodes Check…..674
Diode Bridge Check…..674
Delco and Leece-Neville Alternators…..674
Motorola Alternators…..674
Rotor Field Winding Check…..675
Stator Windings Check…..676
Voltage Regulator Check…..676
Troubleshooting…..676
hyster-899788-03-02-srm0107…..681
toc…..681
High Energy Ignition (HEI) System…..681
Safety Precautions Maintenance and Repair…..682
Description…..685
Distributor Repair…..687
Remove…..687
Disassemble…..687
Assemble…..692
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…..693
Install, If Crankshaft WAS Rotated when Distributor was Removed…..693
Ignition Coil Replacement…..694
Some Four- and Six-Cylinder Models…..694
Remove…..694
Install…..695
V8, Some Four- and Six-Cylinder Models…..695
Remove…..695
Install…..696
Electronic Module Replacement…..697
Remove…..697
Install…..697
Sensing Coil Replacement…..698
Remove…..698
Install…..698
Spark Plugs Replacement…..698
Remove…..698
Install…..699
Visual Check…..699
High Voltage Wires Check…..699
Ignition Coil Check…..700
Coil in Distributor Cap Design…..700
Separate Coil Design…..700
Sensing Coil, Check…..701
Electronic Module Check…..701
Ignition Timing Adjustment…..701
GM V8-366 (6-liter) Ignition System Check…..703
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …..703
Specifications…..703
Troubleshooting…..704
Drive Axle…..973
Safety Precautions Maintenance and Repair…..974
General…..977
Description…..977
Drive Axle Repair…..978
Disassemble (Type 1 Shown)…..978
Clean…..981
Inspect…..981
Assemble (Type 1 Shown)…..982
Torque Specifications…..985
Troubleshooting…..986
hyster-910076-10-03-srm0054…..989
toc…..989
Steering Control Unit…..989
Safety Precautions Maintenance and Repair…..990
General…..993
Description…..993
Operation…..993
Steering Wheel and Column Assembly Repair…..995
Steering Column Assembly Repair…..995
Type A Steering Column Assembly…..995
Remove and Disassemble…..995
Assemble and Install…..997
Type B Steering Column Assembly…..999
Remove and Disassemble…..999
Assemble and Install…..999
Steering Control Unit…..1002
Disassemble…..1002
Clean…..1005
Assemble…..1006
System Air Removal…..1011
Troubleshooting…..1011
Hydraulic Gear Pumps…..1039
Safety Precautions Maintenance and Repair…..1040
Description…..1043
Operation…..1044
Flow Control Valve…..1044
Relief Valve…..1045
Hydraulic Gear Pump Repair…..1045
Remove…..1045
Disassemble…..1046
Clean…..1046
Inspect…..1047
Assemble…..1050
Install…..1052
Pump Output Check…..1052
Method No. 1…..1052
Method No. 2…..1053
Hydraulic System Air Check…..1054
Troubleshooting…..1055
Tilt Cylinders…..1081
Safety Precautions Maintenance and Repair…..1082
General…..1085
Description…..1085
Tilt Cylinder Repair…..1085
Remove…..1085
Disassemble…..1085
Clean…..1085
Assemble…..1086
Tilt Cylinders With O-Ring or Single-Lip Seals…..1086
Tilt Cylinders for XM and XMS Models…..1087
Tilt Cylinders for H700-800A and Early Model H700-920B…..1088
Install…..1089
Tilt Cylinders Using Chevron Packing…..1090
Install…..1091
Tilt Cylinder Leak Check…..1093
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…..1094
Torque Specifications…..1095
Piston Rod Nut…..1095
Retainer…..1096
Troubleshooting…..1098
tables…..1081
Table 1. Movement Rates (Maximum) for Tilt Cylinders…..1094
hyster-910107-02-01-srm0106…..1101
toc…..1101
Starter…..1101
Safety Precautions Maintenance and Repair…..1102
General…..1105
Description and Operation…..1105
Starter Repair…..1107
Remove…..1107
Disassemble…..1107
Clean…..1108
Assemble…..1108
Install…..1109
General Checks and Adjustments…..1109
Troubleshooting…..1112
hyster-910110-12-03-srm0143…..1117
toc…..1117
Instrument Panel Indicators and Senders…..1117
Safety Precautions Maintenance and Repair…..1118
General…..1121
Description…..1122
Steering Column Gauges, Meters, and Indicators…..1122
LED Display Panel…..1122
Battery Discharge Indicators…..1122
Brush Wear Indicators…..1129
Motor Temperature Indicators…..1129
LX Series Display Panel…..1131
Hourmeter Functions…..1131
Battery Indicator Function…..1132
Status Code Function…..1133
ZX Series Display Panels…..1133
Display Panel…..1133
Basic Display Panels…..1133
Performance Display…..1136
Brush Wear Indicators…..1139
Adjustments – General…..1140
Replacement – General Information…..1140
Meter Replacement…..1141
Sender Replacement…..1142
Fuel Level Sender…..1142
Pressure and Temperature Sender…..1142
ITW Display Panel Replacement…..1143
Remove…..1143
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…..1144
Remove…..1144
Display Panel Assembly, Replace…..1144
Indicator LEDs…..1145
Battery Indicators…..1145
Digital Display (Performance Display Panel Only)…..1145
Status Code or Performance Level Switches and Indicator LEDs (Pe…..1145
Basic Display Panel, Replace Parts…..1145
Performance Display Panel, Replace Parts…..1147
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…..1148
Remove and Replace…..1148
Specifications…..1148
Meter Specifications…..1148
Sender Specifications…..1149
Troubleshooting…..1149
Lift Cylinders…..1185
Safety Precautions Maintenance and Repair…..1186
Safety Procedures When Working Near Mast…..1189
General…..1193
Description…..1193
Lowering Control Valve…..1193
Cylinders (General)…..1196
Cylinders (H520-620B, H700-800A)…..1196
Retainer, Install…..1196
Cylinders (H360-460B)…..1198
Cylinders (Two-Speed)…..1200
Lift Cylinder Repair…..1202
Lift Cylinder Removal Without Removing Mast…..1202
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…..1202
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…..1202
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …..1202
Disassemble…..1204
Assemble…..1204
Lift Cylinder Installation in Mast…..1206
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…..1206
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…..1206
Chevron-Style Packing…..1206
Chevron-Style Packing Installation on Piston…..1207
Chevron-Style Packing Installation in Packing Gland…..1209
Lift Cylinders for VISTA® Masts…..1210
Description…..1210
Lowering Control Valve…..1210
Remove…..1212
Disassemble…..1213
Assemble…..1214
Install…..1215
Main Lift Cylinders…..1215
Free-Lift Cylinder…..1215
Lift System Leak Check…..1216
Specifications…..1217
Troubleshooting…..1218
tables…..1185
Table 1. Lift Trucks with Two-Speed Lift Cylinders…..1201
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…..1217
Metric and Inch (SAE) Fasteners…..1245
Safety Precautions Maintenance and Repair…..1246
General…..1249
Threaded Fasteners…..1249
Nomenclature, Threads…..1249
Strength Identification…..1250
Cotter (Split) Pins…..1250
Fastener Torque Tables…..1255
Conversion Table…..1257
Table 1. Bolts and Screws…..1251
Table 2. Studs and Nuts…..1252
Table 3. Torque Nuts…..1253
Table 4. Torque Nuts With Nylon Insert…..1254
Table 5. Torque Values for Metric Fasteners*…..1255
Table 6. Torque Values for Inch Fasteners*…..1256
Table 7. Conversion Table for Metric and English units…..1257
Table 8. Cotter Pin Dimensional Data…..1258
Hyster H40-50J, H60JS (F003) Repair Service Manuals